Method and System for Configurable Fit Shoes

ABSTRACT

A footwear system comprising an external chassis comprising a flexible upper attached to a molded cushion and grip component further comprising a molded midsole, a plurality of interchangeable internal cushion and fit components that fit inside the external chassis and are held in place by an interference fit, wherein the internal cushion and fit components comprise different morphologies and can be replaced by the user without the use of any tools.

BACKGROUND OF THE INVENTION

The present disclosure relates generally to articles of footwear, and more particularly, to a system of fitting used in athletic footwear, particularly running shoes.

Athletic shoes are typically designed and manufactured around a universal last, a shape that represents a generic foot. A universal last is intended to fit as many feet as possible, relying on material deformation to accommodate specific variations in foot features. Typical athletic shoe brands spend a good deal of time and money developing this one shape for the universal last. One result of this is that runners and athletes often pick a brand and shoe model that fits them based on the characteristics of that company's universal last.

Footwear built around the shape of a universal last, however, changes over time often due to seasonal redesigns or through the use of new materials and manufacturing processes. These changes may affect the athlete's perception of the shoe's comfort and performance. Runners and athletes depend on accurate and consistent footwear to maintain their training regimens. There are currently no footwear brands that consider the spectrum of foot shapes, build products based on these shapes and preferences and deliver that consistently to the user.

In traditional footwear manufacturing, the shoe consists of two primary elements, a flexible textile-based upper and a molded foam sole. With this method, the sole unit is permanently adhered underneath the upper, providing all of the cushioning and wear resistant elements of the shoe.

Traditionally, the sole of the shoe is made of three sections that perform specific roles; the insole, the midsole, and the outsole. The insole is traditionally a removable element that sits internally at the base of the upper and serves as a thin layer of foam buffer between the upper and the sole. The midsole is a foam unit often comprised of materials such as polyurethane or ethyl vinyl acetate (EVA) that provides the majority of cushioning for the article of footwear. Last is the outsole, which is often a layer of highly durable carbon or blown rubber that sits at the bottom of the sole unit and makes contact with the ground.

Constructing footwear using a “drop-in” midsole method as disclosed here is distinguished by where the midsole cushioning of the shoe is located. Traditionally, as stated above, footwear cushion is primarily located in a midsole that is permanently adhered to the base of the shoe upper. The drop-in method differs by placing the majority of the shoe midsole cushion internally, where the insole is normally located. This allows the cushioning of the shoe to be installed and removed from the base of the upper, creating a soft surface that the foot can rest on in the shoe.

Currently in footwear there exists a split between the footwear manufacturers and aftermarket insole manufacturers that create various insole geometries in order to adjust the internal shape of an article of footwear. This current product ecosystem is flawed because the insole manufacturer does not have the geometric data of the shoe manufacturer in order to ensure proper function within the shoe. Likewise, the footwear manufacturer does not know if the user will add an aftermarket insole to their shoe in order to customize the internal shape, thus they put very little effort into the insole included with the shoe.

Fitting is also flawed. Currently, athletic shoes are fitted by a retailer or at home in an unsupported manner. The retail experience can be rushed and overwhelming for the user, with a typical expert fitting lasting +/−20 minutes. For the user this experience introduces risk due to the likelihood that the footwear reveals unanticipated qualities after a break-in period. For a user that depends on their physical regimen an improperly tit shoe can present disruption in that regimen and risk of physical injury.

The on-line retail experience can present a more comfortable and convenient experience for the user, however the user is left to select a range of products that may not represent an intentional spectrum of fits. The random nature of this experience can produce frustration and waste for the user and the retailer.

Current systems also do not provide for restoration of footwear. There are many factors that contribute to the degradation or athletic footwear. Runner weight and style can cause foam to degrade at different rates, indoor versus outdoor use can cause materials to wear faster or slower, and finally athlete sensitivity to wear or a specific replacement regimen. For many athletes the shoes may look acceptable, but the foam or other material qualities have degraded to a point that may introduce risk of injury.

Currently, the athlete has a choke to continue use of the shoe, or buy a new shoe.

The present invention provides a cushioning system that gives the athlete the choice to restore the performance of the shoe by inserting a new internal cushion and lit component. Restoring the cushion has many benefits to the athlete: it allows them to refresh more frequently and inexpensively to avoid injury, and it also enables athletes to refresh when away from home, as internal cushion and fit components are more convenient to transport.

Typical athletic mass-market footwear is also not influenced by individual athlete feedback and preferences. The way footwear is mass-produced and sold makes it difficult to know at a detailed level how the product is working for users. Typical footwear manufacturers strive to produce products that satisfy the highest number of individuals by creating generic or universal approaches to fit and comfort.

Athletic footwear retailers have attempted to create individualized fit by combining aftermarket insoles with mass produced footwear. When two components that were not designed to work together are combined, arriving at the desired fit is inconsistent and difficult to repeat. Using two components divides the job of cushioning from form fitting and they fail to integrate the best experience for the athlete.

SUMMARY OF THE INVENTION

A footwear system comprising an external chassis comprising a flexible upper attached to a molded cushion and grip component further comprising a molded midsole, a plurality of interchangeable internal cushion and fit components that fit inside the external chassis and are held in place by an interference fit, wherein the internal cushion and fit components comprise different morphologies and can be replaced by the user without the use of any tools.

In various embodiments, the user of the system may be provided with three different internal cushion and fit components.

In various embodiments, the molded midsole is attached directly to the flexible upper, and the external chassis comprises a heel outsole zone bonded to the rear of the external chassis midsole surface and separated by an area with no rubber in the midfoot.

In various embodiments the internal cushion and fit component locates in external chassis by interference fit with the lower portion of the chassis's internal surfaces and is held in place by an annular interference fit.

In various embodiments the bottom surface of the internal cushion and fit component provides laminar airflow and mechanical interface between the internal cushion and fit component and the external chassis.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overview of the footwear development process.

FIG. 2 is an exemplary illustration of a pair of internal cushion and fit components in accordance with the present invention.

FIG. 3 is an exemplary illustration of a section view of a chassis with an internal cushion and fit component in accordance with the present invention.

FIG. 4 is an exemplary illustration of installation of an internal cushion and fit component in a chassis in accordance with the present invention.

FIG. 5 is an exemplary illustration of a cushion and fit component in accordance with the present invention.

FIG. 6 is an exemplary illustration of a left foot medial view of an external chassis in accordance with the present invention.

FIG. 7 is an exemplary illustration of a bottom view of an external chassis in accordance with the present invention.

FIG. 8 is an exemplary illustration of a three internal cushion and fit components in accordance with the present invention.

FIG. 9 is an exemplary image of a try-on kit in accordance with the present invention.

FIG. 10 is an exemplary image of a try-on kit in accordance with the present invention.

FIG. 11 is an exemplary image of a try-on kit in accordance with the present invention.

FIG. 12 is an exemplary cut-away illustration of athletic footwear in accordance with the present invention.

FIG. 13 is an exemplary illustration of the bottom surface of an exemplary internal cushion and fit component in accordance with the present invention.

FIG. 14 is an illustration of exemplary embodiments of three (3) different initial internal cushion and fit components in accordance with the present invention.

FIG. 15 is an illustration of exemplary embodiments of three (3) different initial internal cushion and fit components in accordance with the present invention.

FIG. 16 is an illustration of exemplary embodiments of three (3) different initial internal cushion and fit components in accordance with the present invention.

FIG. 17 is an illustration of an exemplary embodiment of an initial internal cushion and fit components in accordance with the present invention.

FIG. 18 is an exemplary illustration of the sole of athletic footwear in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is a modular drop-in midsole system and method for running, walking, and casual footwear that provides improved comfort and fit, fitting using a try-on kit and extended trial period, restoration of performance and extended life, and iterative fitment to create better fit and function over time.

Improved fit is delivered by addressing a range of foot shapes and performance preferences. The system utilizes a set of components with varied physical form and material attributes in order to provide a user's desired fit and performance characteristics.

Referring to FIGS. 1-4, the desired fit and performance is achieved using interchangeable internal cushion and fit components 103 paired with an external chassis 104. The initial set of internal cushion and fit components 103 provide distinct fits based on representative foot shapes selected from a cross-section of foot morphologies.

The external chassis 104 serves to position and retain the internal cushioning components 103 as well as provide mechanical and material adhesion to the road or running surface via individually placed rubber grips (outsoles). The external chassis provides a range of complimentary tit and comfort characteristics such as lateral heel stability, a structured raid-foot saddle to align the foot on the internal cushioning component, and a flexible mesh for forefoot breathability.

Referring to FIGS. 7 through 9, the present invention also includes a method for footwear fitting that guides the user through a series of physical fit components across a spectrum of foot shapes and preferences. This engineered cross-section of fits can be experienced in the activity of the user's choice, ensuring the fit is correct and that the footwear performs as expected over time. This “try-on kit” 200 is supported by service experiences ranging from printed instructions to live fitment help. The fitting experience is presented to the user in a physical manner either in a box or other method of containing the required footwear components.

The footwear components in the try-on kit 200 are an external shoe chassis 104 and an array of internal cushion and fit components 103. The user is guided through the experience, which incorporates an extended trial period, a long walk or a series of runs, to evaluate the best fit for the individual. The try-on kit 200 is sent to the user through a parcel service or post office and the user will be able to determine the right fit in a convenient place for them. Unused elements may be shipped back to the supplier.

The present invention also includes a system of athletic shoe components that enables the restoration of cushion and performance without disposal of the footwear. The modular quality of the footwear system enables the user to replace the internal cushion and fit component 103, which provides the majority of the functional performance. The two main components are the external chassis 104 and the internal cushion and fit component 103. If the external chassis remains suitable for the athlete, the internal cushion and fit component can be replaced by the user without the need for any tools and the function, fit and preferences, restored. This allows the user to extend the life of the shoe.

Referring to FIG. 1, the present invention also includes a method for creating better fitting and functioning athletic footwear through a process of iteration and testing with the end consumer that produces increasing resolution through product expression for specific foot morphologies and gait cycles over time. Athletes are segregated by foot morphology and preference, through a process of censored quantitative measure and qualitative feedback we identify opportunities to improve overall product experience. This approach requires direct connection with the end user and feedback on the product.

This method provides a process of continuous improvement for athletic footwear that creates increasingly athlete-specific performance footwear. The present invention combines individual foot morphologies with preferences to establish the basis for iteration of a continuous improvement strategy. The development process leverages cohorts that share foot morphology and preference to inform improvements in product performance. The process continues to gain fit and performance resolution over time as footwear models are tested and validated with athletes. The combination of foot morphology and preference is the core tenet of the process.

As shown in FIGS. 2 through 6 and 11 through 13, the footwear system is comprised of an external chassis 104 and an internal cushion and fit component 103. The principal function of the external chassis 104 is to provide heel support, neutral gait support, mechanical and material adhesion, and a platform for the internal cushion and fit components. The principal function of the internal cushion and fit components 103 is to provide fit and dynamic comfort for specific runner foot morphologies.

The external chassis 104 is built around a last designed to address a range of foot morphologies in concert with the internal cushion and fit component. A footwear last is the shape that defines the internal volume of a piece of footwear. The last of the present invention is unconventional due to its role in creating volumetric affordances for the upper as well as the internal cushion and fit components through the footwear creation process. A combination of foot scan data from selected foot morphologies may be adjusted for dynamic use such as running and augmented by gait cycle preferences to inform the internal cushion and fit components.

The external chassis 104 is comprised of a flexible upper 126 of textile-based assembly that is sewn or bonded together to create a shape that resembles a foot, paired with molded cushion and grip components 170.

The three main components comprising the flexible upper are the shell pattern 105, the tongue assembly 111, and the strobel component 112. The shell pattern incorporates discrete reinforcement features that provide added strength around the midfoot saddle area 10 and the heel 109. The textile-based mesh forefoot section incorporates discrete toe reinforcement 106 and breathable zones across the vamp 107. The textile-based heel section incorporates heel capture affordances that interface with the athlete's foot in the form of foam padded heel feature 110.

The flexible upper 126 is attached to molded cushion and grip foam and rubber components 170 or tooling. Directly attached to the upper is the foam midsole 127. The foam midsole 127 provides reinforcement for the upper 126 to accurately locate the internal cushion and fit component 103 with a shallow cup feature 128 around the upper edge. The foam midsole 127 is the primary bonding surface for the upper 126 to adhere to.

In medial and lateral side view the foam midsole 127 has heel stability features 119 that project upward just forward of the heel. These projections provide heel stability that decreases 118 as the runner progresses through the gait cycle. The midsole 127 is designed to provide symmetrical support, with no bias toward either lateral or medial foot motion. In various embodiments, the midsole 127 component may be 55 Asker C hardness.

Referring to FIG. 18, the Thant midsole acts as a locator for molded rubber grip components or outsoles. The molded rubber outsoles are divided into two main functional zones characterized by variations on grip, durability, and flexibility. The heel outsole zone 125 is bonded to the rear of the chassis midsole surface and is separated by an area with no rubber in the midfoot 121. In the heel the outsoles are bonded to the foam chassis midsole leaving flex grooves or thinned material features designed to flex 124.

The heel outsole components 125 are made of a material designed for cushion and durability. The forefoot outsole material begins with a rubber toe tip and covers the majority of the forefoot terminating in the midfoot gap. In the forefoot the outsole components 122 are softer and provide more material grip than the rear outsole components. The forefoot outsole rubber is divided into smaller features 123 to provide more flexibility and increased mechanical grip.

The flexible upper 126 and molded midsole 127 that form the external chassis 104 are designed to accept the internal cushion and fit component 103. Referring to FIG. 12, the internal cushion and fit component 103 may locate in the volume of the chassis by interference fit with the internal surfaces 128. In various embodiments, the specific features that locate the internal component are the bottom surface and lower of the chassis's internal surfaces, leaving the top surface of the internal cushion and fit component 103 to interface with the athlete's foot. The annular interference fit is designed to reduce migration of the internal cushion and fit component 103 relative to the external chassis 104.

Referring to FIG. 13, molded grip features 129 in the internal cushion and fit component 103 provide laminar airflow and mechanical interface between the internal cushion and fit component 103 and the external chassis 104.

Referring to FIGS. 14-17, in various exemplary embodiments three (3) different initial internal cushion and fit components 103 may be provided. It will be understood by those of skill in the art that a different number of different internal cushion and fit components could be provided.

The three (3) different initial fit components described herein are designated for convenience as “A” (FIG. 14), “B” (FIG. 15), and “C” (FIG. 17), and are based on a combination of factors, including specific foot morphologies selected based on the concentration of athlete runners, existing product that addresses selected morphology, and runner preferences gained through wear testing feedback. These internal cushion and fit components 103 represent specific fits arranged across the spectrum of foot shapes. The cushion and fit components employ a range of physical features to address runner foot shape, gait cycle and feel preferences.

The physical and material variables of the internal cushion and fit component 103 may include arch height, arch position, forefoot concavity, heel capture, toe spring, heel to toe offset, durometer, durometer placement, medial/lateral stability. Referring to FIG. 17, there is a reference plane 141. The variations among the different internal cushion and fit components 103 in the physical shapes based on morphologies and preferences are above reference plane 141. Below the reference plane 141 the physical shapes are similar to ensure proper fit with the chassis.

Referring to FIG. 14, in various embodiments the cushion and fit component “A” is a synthesis of a low volume, high forward positioned arch, narrow heel, and wide forefoot morphology and the dynamic performance preferences recorded through wear testing. Above the reference plane 141 in example “A” the internal cushion and fit component 103 is defined by a 16.5 mm arch height (Section B1-B2), 14 mm heel cup (Section C1-C2), 50 c forefoot 130, 45 c heel 131, and 25 c top surface 132.

Referring to FIG. 15, in various embodiments the cushion and fit component “B” is a synthesis of a mid-volume, middle positioned arch, medium width heel, and wide forefoot morphology and the dynamic performance preferences recorded through wear testing. Above the reference plane 141 in example “B” the internal cushion and fit component 103 is defined by a 12.5 mm arch height (Section B1-B2), 10 mm heel cup (Section C1-C2), 55 c medial arch support 135, 50 c forefoot 134 and heel, and 25 c top surface 136.

Referring to FIG. 16, in various embodiments the cushion and fit component “C” is a synthesis of a high volume, low middle positioned arch, wide heel, and wide forefoot morphology and the dynamic performance preferences recorded through wear testing. Above the reference plane 141 in example “C” the internal cushion and fit component 103 is defined by a 8.5 min arch height (Section B1-B2), 6 mm heel cup (Section C1-C2), 50 c full length platform 138, and 25 c top surface 139.

The present invention solves the issue of finding the right shoe fit through a geometry-based system of interchangeable internal cushion and fit components 103. Each internal cushion and fit component uniquely addresses a specific group of foot shapes while all fit into a single external chassis. In various embodiments, a range of different internal cushion and fit components may be provided addressing any combination of fit and performance characteristics.

Referring to FIGS. 7-9, in various embodiments, the system may include a try-on kit 200, consisting of three main components: an external chassis 104, a curated range of internal fit and cushion components 103, and the primary secondary packaging of the try-on kit 200.

The user may determine the size of the external chassis 104 and internal fit and cushion components 103 in advance of receiving the try-on kit 200. There are many possible ways to make this determination: the user may select their size via a website app or through a retailer. The desired size is initially determined by US, EU, UK, or Imperial Increments.

The try-on kit 200 sent directly to the user's desired physical destination i.e. home or office, in the case of retail deployment the try-on kit may be brought to the user physically by a sales associate.

The user may receive, step-by-step instruction through the try-on kit experience prior to, and during the try-on experience. Prior to the try-on experience the user may be shown instructions on how to use the kit, and the benefit of running in their preferred environment in order to set the best context for evaluation, afford added convenience, and increased efficacy to the try-on and shoe selection process.

The user will be directed to install the internal fit and cushion component 103 “A” into the chassis and evaluate it based on the user's representative activity. The user will be given specific qualities to keep in mind while running or walking. The user will be guided in recording these qualities in a feedback matrix. The user will the be directed to install the internal fit and cushion components 103 “B” and “C” into the chassis on subsequent use and collect feedback for use in footwear selection and to aid in the development of improved fit. Once the user has identified their best functioning combination, which may be any combination of internal fit and cushion components, they may return the unselected components.

The internal fit and cushion components 103 included in the try-on kit 200 may present the user with a size gradation of fit and performance features: Arch height, arch position, forefoot concavity, heel capture, toe spring, heel toe offset, durometer, durometer placement, medial/lateral stability. The user's progression through the presented range internal fit and cushion components creates a systematic approach to identifying the user's desired fit.

In various embodiments, the system may include an athletic footwear restoration system that enables the user to refresh the function and fit of articles of footwear without replacing the entire shoe. The system of footwear components separates the functions of the shoe in two categories of wear duration, faster wear and slower wear.

Wear is defined both by the user and the manufacturer: the user will determine wear in some cases by the way using the product makes them feel, often using pain as indication of wear, The user will also objectively evaluate the physical integrity of the shoe to determine wear levels. The manufacturer will use objective performance metrics to determine material function, foam and rubber rebound, material and mechanical grip, and fit integrity.

The faster wearing functions of the shoe are addressed by the internal cushion and fit component 103. The internal cushion and fit component variations are made of a composite of various foam densities whose function degrades faster than the materials found in the external chassis 104 component. The slower wear materials and functions are in the external chassis 104, which consists of textiles, multi-density rubber, laces and eyelets, and heel and midfoot stability components. The rate of physical wear of the chassis component is affected by runner weight, running style, terrain, and other factors.

Each athlete using this footwear system will make a choice as to the best fit represented by the selection of an internal cushion and fit component 103. The athlete will make the determination that their footwear performance is below a threshold that they would like. The athlete may be given the option to purchase both an external chassis 104 and internal cushion and fit component 103, or only the internal cushion and fit component. If they select the internal cushion and fit component option, they may specify which configuration they have been using or wish to use and order that configuration. The internal cushion and fit component may be shipped directly to the end user. The end user then removes the existing internal cushion and lit component 103 and replaces it with the new internal cushion and fit component. Replacement of the internal cushion and fit component benefits the athlete by helping keep them active for less money.

The form and material factors that contribute to better performing footwear are manifold. In an effort to identify and apply the most effective physical forms and material qualities, in various embodiments a process of experimentation can be used that starts with actual runner's feet. The process began with a comprehensive examination of foot morphologies across genders and regions. Through this process one may establish a foundation of physical elements, arch height, arch position, foot volume, instep volume, met head position, heel width, heel shape, forefoot width, forefoot shape.

When examining the spectrum of morphologies, one may identify three instances where the macro-level attributes varied the most requiring a different physical approach. Footwear may he built to fit the three morphologies and tested using separate runner control groups. Different rounds of testing may be used to isolate specific footwear geometries, material density/hardness, and flexibility and surface qualities. With each round of testing users may provide feedback on the footwear and established “preference” as an input to the design process.

The cross-section of initial fits disclosed herein were identified through the following process. The spectrum of foot shapes were established via scan data and footwear development experience, macro level foot morphology targets were established as initial fits and tested with target athletes. The target athletes provide feedback, informing improvement efforts. This development process is focused on revealing this intersection in greater and greater resolution. 

What is claimed is:
 1. A footwear system comprising: an external chassis comprising a flexible upper attached to a molded cushion and grip component further comprising a molded midsole, a plurality of interchangeable internal cushion and fit components that fit inside the external chassis and are held in place by an interference fit, wherein the internal cushion and fit components comprise different morphologies and can be replaced by the user without the use of any tools.
 2. The footwear system of claim 1, wherein the user is provided with three different internal cushion and lit components.
 3. The footwear system of claim 1, wherein the molded midsole is attached directly to the flexible upper.
 4. The footwear system of claim 1, wherein the external chassis comprises a heel outsole zone bonded to the rear of the external chassis midsole surface and separated by art area with no rubber in the midfoot.
 5. The footwear system of claim 1, wherein the internal cushion and fit component locates in external chassis by interference fit with the lower portion of the chassis's internal surfaces.
 6. The footwear system of claim 1, wherein the internal cushion and tit component is held in place by an annular interference fit.
 7. The footwear system of claim 1, wherein the bottom surface of the internal cushion and tit component provides laminar airflow and mechanical interface between the internal cushion and fit component and the external chassis. 